Burner control units BCU 480

Transcription

1 Burner control units BCU 480 roduct brochure GB 6 Edition. For pilot and main burners in intermittent or continuous operation Replace the local control cabinet Flame control by UV, ionization or a further option of using the furnace chamber temperature Display of the program status, unit parameters and flame signal; Manual mode for burner adjustment and for diagnostic purposes Visualization and adaptation to the specific application via the C programming and diagnostic software BCSoft to simplify logistics management Air valve control relieves the furnace control Optional ROFIBUS D interface EC type-tested and certified Certified for systems up to SIL 3 and compliant with L e

2 BCU 480 Edition. Application The BCU unites the functionally interrelated components of automatic burner control unit, ignition transformer, Manual/ Automatic mode and display of operating and fault statuses in a compact metal housing. The burner control units BCU 480 control, ignite and monitor gas burners for intermittent or continuous operation. As a result of their fully electronic design, they react quickly to various process requirements and are therefore suitable for frequent cycling operation. They can be used for industrial burners of unlimited capacity which are ignited by pilot burners. ilot and main burners may be modulating or stage-controlled. The BCU 480 monitors pilot and main burners independently. The pilot burner can burn permanently or be switched off. The BCU is installed near the burner to be monitored. On industrial furnaces, the BCU reduces the load on the central furnace control by taking over tasks that only relate to the burner, for example it ensures that the burner always ignites in a safe condition when it is restarted. The air valve control assists the furnace control for cooling, purging and capacity control tasks. The program status, the unit parameters and the level of the flame signal can be read directly from the unit. The burner can be controlled manually for commissioning and diagnostic purposes. If the local requirements on the burner control unit change, the C software BCSoft can be adjusted to the unit parameters of the application by using the optical interface. The service personnel is supported by a convenient visualization system of the input and output signals and the error history. The new power management scheme reduces installation and wiring costs. The power for the valves and ignition transformer is supplied via the power supply of the BCU, protected by a replaceable fine-wire fuse. The conventional wide-spread systems used in industrial furnace and kiln construction require bridging of large distances for signal processing. The optionally available BCU..B for connection to the ROFIBUS D fieldbus is equipped for this purpose. As a standardized fieldbus system, the ROFI- BUS D considerably reduces development, installation and commissioning costs compared to conventional wiring. The use of a standard bus system offers massive benefits compared to manufacturerspecific bespoke solutions. Time-tested hardware components, standardized connection methods and a series of tools of bus diagnostics and optimization are available on the market from a whole range of manufacturers. The widespread use of the system ensures that the planning and service personnel are very familiar with how the system operates and how to handle it and can therefore operate the system efficiently.

3 BCU 480 Edition. 3 Bogie hearth forging furnace in the metallurgical industry Intermittent shuttle kiln in the ceramics industry Walking beam furnace with overhead firing

4 4 BCU 480 Edition. Examples of application BCU L, N, E 3 VBY SS LC AI A ϑ ϑ Stage-controlled main burner with alternating pilot burner Control: Main burner ON/OFF. The main burner can be started with reduced capacity after the operating signal from the pilot burner has been detected. The pilot burner is switched off automatically after the main burner has started up. When the main burner is switched off, the pilot burner automatically switches on again. This reduces the main burner start-up time. A UV sensor monitors the flame signal from pilot and main burners. UV sensor UVD is used for continuous operation, UV sensor UVS for intermittent operation. The BCU provides the cooling and purging processes. VAG UV VR..L ϑ ϑ t BCU L, N, E 3 SS LC AI A ϑ ϑ Stage-controlled main burner with permanent pilot burner Control: Main burner ON/OFF. The main burner can be started with reduced capacity after the operating signal from the pilot burner has been detected. ilot and main burners can be operated simultaneously. This reduces the time required by the main burner for starting up. The BCU provides the cooling and purging processes VBY VAG VR..R ϑ ϑ t

5 BCU 480 Edition. 5 BCU L, N, E 3 SS LC AI A ϑ ϑ Two-stage-controlled main burner with permanent pilot burner Control: Main burner ON/OFF with ignition via bypass. The main burner can be started at low-fire rate after the operating signal from the pilot burner has been detected. When the operating state is reached, the BCU issues the Enable signal for the maximum burner capacity. ilot and main burners can be operated simultaneously. This reduces the time required by the main burner for starting up. The BCU provides the cooling and purging processes. VBY VAS VAG 4 7 M IC ϑ ϑ t BV BCU L, N, E ma SS LC AI ϑ 4 ϑ Modulating-controlled burner Control: Main burner continuous. The butterfly valve for air is moved to ignition position in order to start the main burner. The main burner can be started at low-fire rate after the operating signal from the pilot burner has been detected. The control system controls the burner capacity via the butterfly valve for air after the operating state has been signalled. ilot and main burners can be operated simultaneously. This reduces the time required by the main burner for starting up. VBY VAG M BV+IC

6 6 BCU 480 Edition. L, N, E SS LC AI BCU 480..B 6 BUS BUS ROFIBUS-D BCU 480..B BCU 480..B 6 BUS 6 BUS BCU 480..B for ROFIBUS D The bus system transfers the control signals for starting, resetting and for controlling the air valve from the control system to the BCU 480..B. In the opposite direction, it sends operating status, the level of the flame signals and the current program status. Control signals that are relevant for safety, such as the safety interlocks, purge (optional) and digital input, are transferred independently of the bus communication by separate cables. BCU 480..D STM > 750 C L BCU 480..D BCU 480..D: High temperature equipment Indirect flame control using the temperature. During the start-up process, as long as the wall temperature is below auto ignition temperature, the flame must be controlled by conventional methods. When the working temperature has exceeded 750 C, the safety temperature monitor (STM) takes over the indirect flame control. Selection T /3 /5 / / L W R 3 8 GB ) ) D D3 S S3 / /3 U C B / E BCU 480 Order example BCU 480-5/3/LW3GBCE = standard, = available. ) Not available for BCU..T. ) Not in conjunction with ROFIBUS D (BCU..B).

7 BCU 480 Edition. 7 Technical data Mains voltage: 30 V AC, -5/+0%, 50/60 Hz, 5 V AC, -5/+0%, 50/60 Hz, for grounded and ungrounded mains. Inherent consumption: approx. 9 VA plus inherent consumption of the integrated ignition transformer [50/60 Hz]. Voltage to inputs and valves = mains voltage. Signal and control line: max..5 mm (AWG 4). Cable for burner ground/e wire: 4 mm (AWG ). Cable gland: 5 cable glands with multiple seal inserts for cable diameters of up to 7 mm, BCU..: with cable glands and an industrial chassis plug. Each BCU is supplied for two cable glands with one seal insert each for cable diameters between 7 mm. Input voltage of signal inputs: Rated value 5 V AC 30 V AC Signal Signal Frequency 50/60 Hz 50/60 Hz Input current of signal inputs: Signal : typ. ma Output current: max. A, cos ϕ =, for the valve outputs (or SRC outputs), but total current for valves and ignition transformer: max..5 A Fail-safe inputs and outputs: All the inputs and outputs marked (see connection diagrams) may be used for safety tasks. Flame control with UV sensor or ionization sensor. Flame signal for ionization control: 8 μa, UV control: 35 μa. For intermittent or continuous operation. Maximum length of ignition cable with integrated electronic ignition: 5 m (6.4 ft). Maximum length of ionization/uv cable: 50 m (64 ft). Fuses in unit: F: 3.5 A, slow-acting, H, pursuant to IEC 7-/5. Fuse for protecting the safety-relevant ignition, valve, valve and air valve outputs (terminals 7,, 4 and 6): 5 A, slowacting, not replaceable. F3 (only for BCU.. A, BCU..C and BCU..U): 3.5 A, slow-acting, H, pursuant to IEC 7-/5. Operation and fault signalling contacts: Signalling contact for mains voltage, max. A, 53 V, not internally fused. Number of operating cycles: Relay outputs: 50,000 pursuant to EN 98, Mains switch:,000, Reset/Information button:,000. Ambient temperature: -0 to +60 C (-4 to +40 F), climate: no condensation permitted. Enclosure: I 54 pursuant to IEC 59. Weight: approx. 5 kg ( lb) depending on version. Ignition Input Output transformer V AC Hz* A* V ma* TZI 5-5/00W (60) 0.45 (0.35) () TZI 7-5/0W (60). (0.8) (8) TZI 7,5-/00W (60) 0.6 (0.45) 7500 (9) TZI 7,5-0/33W (60) 0.9 (0.7) (5) TZI 5-5/00R 5 50 (60) 0.9 (0.7) () TZI 7-5/0R 5 50 (60). (.6) (8) TZI 7,5-/00R 5 50 (60). (0.9) 7500 (9) TZI 7,5-0/33R 5 50 (60).8 (.35) (5) * Values in ( ) apply to 60 Hz. BCU..B External fuse: A per zone. ROFIBUS D Manufacturer ID: 0x05DB. ASIC type: SC3. SYNC- and FREEZE-capable. Baud rate detection: automatic. Min. cycle time: 0. ms. Diagnostic bytes: 6 (D Standard). arameter bytes: 7 (D Standard).

8 8 BCU 480 Edition. Safety-specific characteristic values In the case of ionization control, SIL 3 suitable for Safety Integrity Level Diagnostic coverage DC 9.7% Type of subsystem Type B to EN 6508-, Mode of operation High demand mode pursuant to EN , 3.5. Mean probability of dangerous failure FH D.9 x 0-8 /h Mean time to dangerous f ailure MTTF d MTTF d = / FH D Safe failure fraction SFF 98.8% The specified values apply for the combination with ionization electrode (sensor) and a unit of the BCU 400 series. No characteristic values are available for flame control with UV sensor. Relationship between the erformance Level (L) and the Safety Integrity Level (SIL) L SIL a b c d e 3 ursuant to EN ISO 3849-:006, Table 4, the BCU can be used up to L e. Max. service life under operating conditions: 0 years after date of production. Detailed information on this product Contact Sales Elster GmbH ostfach Osnabrück Strotheweg Lotte (Büren) Germany T F info@kromschroeder.com We reserve the right to make technical modifications in the interests of progress. Copyright 03 Elster GmbH All rights reserved